EP2807082B1 - Extruded pet parison and manufactured container - Google Patents

Extruded pet parison and manufactured container Download PDF

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Publication number
EP2807082B1
EP2807082B1 EP13741541.0A EP13741541A EP2807082B1 EP 2807082 B1 EP2807082 B1 EP 2807082B1 EP 13741541 A EP13741541 A EP 13741541A EP 2807082 B1 EP2807082 B1 EP 2807082B1
Authority
EP
European Patent Office
Prior art keywords
pet
extruded
polymer
extruded polymer
parison
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Active
Application number
EP13741541.0A
Other languages
German (de)
English (en)
French (fr)
Other versions
EP2807082A4 (en
EP2807082A2 (en
Inventor
William C. Young
Harvey Shannon HOLT
Gates Moss
Michael C. Kitzmiller
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Plastipak Packaging Inc
Original Assignee
Plastipak Packaging Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Plastipak Packaging Inc filed Critical Plastipak Packaging Inc
Priority to PL13741541T priority Critical patent/PL2807082T3/pl
Publication of EP2807082A2 publication Critical patent/EP2807082A2/en
Publication of EP2807082A4 publication Critical patent/EP2807082A4/en
Application granted granted Critical
Publication of EP2807082B1 publication Critical patent/EP2807082B1/en
Active legal-status Critical Current
Anticipated expiration legal-status Critical

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
    • B65D1/02—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents
    • B65D1/0207—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents characterised by material, e.g. composition, physical features
    • B65D1/0215—Bottles or similar containers with necks or like restricted apertures, designed for pouring contents characterised by material, e.g. composition, physical features multilayered
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/03—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the shape of the extruded material at extrusion
    • B29C48/09—Articles with cross-sections having partially or fully enclosed cavities, e.g. pipes or channels
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/16—Articles comprising two or more components, e.g. co-extruded layers
    • B29C48/18—Articles comprising two or more components, e.g. co-extruded layers the components being layers
    • B29C48/21—Articles comprising two or more components, e.g. co-extruded layers the components being layers the layers being joined at their surfaces
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/32—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles
    • B29C48/335—Multiple annular extrusion nozzles in coaxial arrangement, e.g. for making multi-layered tubular articles
    • B29C48/336—Multiple annular extrusion nozzles in coaxial arrangement, e.g. for making multi-layered tubular articles the components merging one by one down streams in the die
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/32—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles
    • B29C48/335—Multiple annular extrusion nozzles in coaxial arrangement, e.g. for making multi-layered tubular articles
    • B29C48/336—Multiple annular extrusion nozzles in coaxial arrangement, e.g. for making multi-layered tubular articles the components merging one by one down streams in the die
    • B29C48/3366—Multiple annular extrusion nozzles in coaxial arrangement, e.g. for making multi-layered tubular articles the components merging one by one down streams in the die using a die with concentric parts, e.g. rings, cylinders
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/25—Component parts, details or accessories; Auxiliary operations
    • B29C48/30—Extrusion nozzles or dies
    • B29C48/32—Extrusion nozzles or dies with annular openings, e.g. for forming tubular articles
    • B29C48/34—Cross-head annular extrusion nozzles, i.e. for simultaneously receiving moulding material and the preform to be coated
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B27/00—Layered products comprising a layer of synthetic resin
    • B32B27/36—Layered products comprising a layer of synthetic resin comprising polyesters
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B65—CONVEYING; PACKING; STORING; HANDLING THIN OR FILAMENTARY MATERIAL
    • B65D—CONTAINERS FOR STORAGE OR TRANSPORT OF ARTICLES OR MATERIALS, e.g. BAGS, BARRELS, BOTTLES, BOXES, CANS, CARTONS, CRATES, DRUMS, JARS, TANKS, HOPPERS, FORWARDING CONTAINERS; ACCESSORIES, CLOSURES, OR FITTINGS THEREFOR; PACKAGING ELEMENTS; PACKAGES
    • B65D1/00—Containers having bodies formed in one piece, e.g. by casting metallic material, by moulding plastics, by blowing vitreous material, by throwing ceramic material, by moulding pulped fibrous material, by deep-drawing operations performed on sheet material
    • B65D1/40—Details of walls
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C48/00—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor
    • B29C48/022—Extrusion moulding, i.e. expressing the moulding material through a die or nozzle which imparts the desired form; Apparatus therefor characterised by the choice of material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B32—LAYERED PRODUCTS
    • B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
    • B32B2439/00—Containers; Receptacles

Definitions

  • the present disclosure relates generally to extrusion blow molding (EBM) methods and systems capable of utilizing injection stretch blow molding (ISBM) grade polyethylene terephthalate (PET) to produce articles including bottles and containers.
  • EBM extrusion blow molding
  • ISBM injection stretch blow molding
  • PET polyethylene terephthalate
  • PET Polymer resins, including PET, are commonly employed in the plastic packaging industry. Because of its favorable processing properties, and because PET is considered recycling-friendly, PET is widely used to produce numerous types of bottles and containers (which may herein be collectively referred to as simply "containers"). In the bottle industry, for example, bottle-grade PET usually has a resin intrinsic viscosity (IV) of about 0.65 to 0.87 dL/g, and is commonly used in connection with ISBM processing.
  • IV resin intrinsic viscosity
  • Extrudable PET-type compositions or formulations are also known in the packaging industry. Without limitation, general parison extrusion teachings are provided in U.S. Patent Nos. 3,919,375 and 4,828,786 .
  • a higher molecular weight PET i.e., one having a higher IV (e.g., 1.0 dL/g or greater) and chain extenders may be needed.
  • co-polymers are commonly amorphous, or slow-crystallizing, which can present certain conversion and reclamation challenges.
  • the resulting container can, among other things, present recyclability challenges. For instance, when the material has not yet crystallized, and remains amorphous, the amorphous co-polymer tends to soften and form agglomerates, typically at around 80°C. Further, when amorphous or slow crystallizing resins are added to the PET recycling stream, the resins can cause, inter alia, unwanted sticking, thermal agglomeration, and bridging (or port plugging) issues. Such issues can make such PET polymer resins unsuitable for conventional recycling programs and processes.
  • the resulting combination of resins may not exhibit performance characteristics that are sufficiently desirable. That is generally from a recycling standpoint, the higher percentage of extrusion-grade PET, the more undesirable the characteristics of the resulting product.
  • the WO 99/65989 A1 disclosing an extruded parison according to the preamble of claim 1, relates to polyester compositions that possess improved gas barrier properties.
  • These novel polyester blends comprise repeat units of phenylenedi (oxyacetic acid).
  • Such polyesters with improved gas barrier properties are useful in packaging applications where low gas permeability are required for protection or preservation of the contents.
  • the US 7,150,371 B1 provides an extrusion blow molded container comprising a closed base, a body portion extending from the closed base having a surface finish that is substantially free of striations, and an open neck portion extending from the body portion.
  • the container is comprised of polyethylene terephthalate (PET);
  • PET polyethylene terephthalate
  • the base portion includes a support portion and a substantially elevated portion having a center and a major diameter; and the center is disposed an elevated distance above said surface that is less than about 0.05 the major diameter.
  • the EP 1 852 467 A1 relates to a barrier layer consisting of a composition comprising a blend of (i) a polyester resin, (ii) a polyamide material and optionally (iii) an oxygen scavenging material.
  • the US 5,444,144 A relates to a process for producing polyethylene terephthalate (hereinafter referred to as "PET") useful for molding bottles, films and sheets. More particularly, it relates to a process for producing PET whereby contamination of a mold scarcely occurs during its molding and the aldehyde content of the molded product will be little.
  • PET polyethylene terephthalate
  • the US 4,340,721 A relates to improved saturated polyesters comprising ethylene glycol terephthalate recurring units, and to containers shaped therefrom useful for the packaging of foodstuffs and beverages. It also relates to a process for the preparation of such improved polyesters.
  • the US 2010/0201015 provides a method of producing a polyethylene terephthalate graft copolymerized resin, comprising subjecting the following mixture to a homogeneous reaction at a temperature of 250 DEG C or higher to impart a high melt viscosity to the mixture.
  • the present invention relates to an extruded parison in accordance with claim 1.
  • the co-extruded parison may be subsequently blow molded to form a container as claimed in claim 4.
  • a first extruded polymer (i.e., a higher IV polymer) comprises PET having an IV of from 0.96 or greater. If desired, the first extruded polymer may have an IV from about 1.0 to 1.4, and is created by solid-stating standard bottle grade PET and may be devoid of chain extenders.
  • a second extruded polymer (i.e., a lower IV polymer) also comprise PET, and has an IV of less than 0.85. Additionally, the second extruded polymer may further comprise post-consumer recycled (PCR) PET and regrind PET, and/or may optionally include a colorant and/or a barrier.
  • PCR post-consumer recycled
  • the extrusion polymer being used may comprise a blend.
  • an extruded PET may comprise a blend - such as a blend of higher IV PET (e.g., 0.96 or higher) and a lower IV PET (e.g., between 0.80 and 0.85).
  • the blend would not require chain extenders and, if desired, may itself be co-extruded.
  • the higher IV polymer material may start as a lower IV polymer material and may have its IV raised, for instance, via a solid-stating process.
  • a method in which two or more polymers are co-extruded to form a parison that can be subsequently blown into a bottle or container.
  • two separate polymers may be provided.
  • a first polymer may comprise PET and may have a comparatively higher IV - e.g., 0.96 or greater (or, for instance, from about 1.0 to about 1.4).
  • the first polymer may, for example and without limitation, be created by solid-stating standard bottle grade PET and may be devoid of chain extenders.
  • a second polymer may also comprise PET and may have a comparatively lower IV - for instance, less than about 0.87 (or, for example, from about 0.8 to about 0.87).
  • the second polymer i.e., having a comparatively lower IV, may comprise post-consumer recycled (PCR) PET and/or regrind PET.
  • the second polymer may additionally include one or more colorants.
  • regrind PET generally differs from PCR PET in that regrind material has not been distributed to the consumer through an article's normal life cycle.
  • regrind material may be material that did not form a part of the article and is simply captured at the manufacturing site.
  • the first polymer may be provided with an IV of, for example, about 0.97, while a second polymer may have an IV of, for example, 0.76.
  • the layer with the comparatively higher IV can serve to handle higher melt temperatures and provide strength, and can additionally help to prevent migration.
  • the first (higher IV) and second (lower IV) polymers may be extruded and combined - e.g., via an extrusion head - to form a single parison having multiple (e.g., two) layers.
  • the cross-sectional thickness (along the sidewall and perpendicular to the centerline of the parison) of the higher-IV layer may be about 20% (0.20) of the total parison thickness
  • the thickness of the lower-IV layer may be about 80% (0.80) of the total parison thickness.
  • the higher-IV layer and the lower-IV layer may be interchanged with respect to which layer is the inner co-extruded layer and which layer is the outer co-extruded layer.
  • Embodiments of bottles and containers produced in accordance with the present disclosure may comprise crystalline PET, may exhibit commercially acceptable clarity, and may be fully recyclable in the standard PET recycling stream (i.e., marked as "No. 1").
  • an extrudable PET - that is not solid-stated - may have a "composite" IV of about 0.96, or less. Such a configuration may be desirable for processes that involve downward extrusion.
  • the invention is not, however, limited to equipment that extrudes in the direction of gravity, and other known techniques may be employed.
  • the disclosed method and system may be applied to parisons formed in one co-extruded layer, or in multi-layer embodiments that have two or more extruded layers.
  • one layer may serve as a carrier layer, while the other layer(s) may impart one or more other structures or features.
  • Such other structures or features may include the use of PCR, coloring (e.g., an outside color), or cost optimization (e.g., inclusion of a comparatively less expensive (“filler”) middle layer).
  • a comparatively high-IV polymer may serve as a skeleton, while another layer may include as much as 28% or more PCR.
  • resulting bottles or containers may comprise a PCR content of between about 10% to 50% by weight, In other embodiments, the PCR content may be in the nature of about 20% to 30% by weight. Moreover, if desired, a junk layer of 80% or more (even up to 100%) PCR may additionally be included.
  • Embodiments of the present disclosure may not depend upon chain extenders, and may not comprise combinations of amorphous and solid state resins. That is, for instance, the extrudable polymers can be provided in a solid state condition, and may not be amorphous.
  • the extrusion polymer may comprise a blend.
  • an extruded PET may comprise a blend - such as a blend of higher IV PET (e.g., 0.96 or higher) and a lower IV PET (e.g., between 0.80 and 0.85).
  • the blend does not include chain extenders and, if desired, the blend itself may be co-extruded.
  • the higher IV polymer material may start as a lower IV polymer material that has its IV raised, for instance, via a solid-stating process.
  • regrind materials are commonly recaptured at a manufacturing site.
  • a manufacturer often would like to re-incorporate regrind materials into the process.
  • the amount of regrind material to be re-introduced can depend upon requirements and various process needs.
  • an over-extensive use of regrind can involve undesirable effects concerning container quality. Such issues may involve streaking, reduced clarity, "unmelts" (resin pieces that have not fully melted), etc.
  • a manufacturer may elutriate the regrind material prior to reincorporating it into the polymer material being extruded.
  • An elutriation process can remove particulate matter or "fines" from the regrind material. Such fines can cause or exacerbate some of the aforementioned issues. While some past processes have been known to crystallize resins to "toughen” them up before being processed in a dryer, the present disclosure teaches, inter alia, the elutriation of regrind material prior to its reuse in extrusion manufacturing, including extrusion PET manufacturing. Because non-elutriated regrind material that has been crystallized may still include fines, an elutriation process can remove such fines. It is noted that if employed, crystallization can occur before or after elutriation. However, for many applications, crystallizing after elutriation may be preferable, and may provide better results.
  • amount of weight of material that is lost. With some embodiments of the concept, it is anticipated that less then 1.5% by weight of material will be lost in connection with elutriation. For some embodiments, amount of loss may be kept within a target range of 0.1 to 1.5 percent by weight.
  • a potential benefit of a dual layer is the ability to utilize a carrier resin. It is also possible to color one or both layers to provide different visual effects, whether the layer or layers are colored alone or in various combinations. The combination of two or more layers, with each layer having its own color, haze, and other visual qualities, can further enhance container decoration and visual appeal. Further, if permeation is a potential issue, one or more barrier layers may be employed in connection with one or more layers of the parison/article.
  • Parisons associated with the disclosed concept may be processed utilizing various forms of known processing techniques and equipment.
  • a "shuttle"-type system may be used. With shuttle-type equipment a head with multiple outlets may provide at least one parison at a common spot and a mold or molds can be moved, or shuttled, in position under the parison. Such a system may work well if space is an issue and/or if production will be more "on demand” with less concern about high capacity and speed.
  • various known rotary or “wheel” extrusion techniques may be employed where a more “continuous" process, with potentially higher speed and output, is desirable.
  • the second extruded polymer has an intrinsic viscosity of about 0.80 to about 0.85.
  • the cross-sectional thickness of the first extruded polymer is at least about 0.20 of the total parison thickness.
  • the cross-sectional thickness of the second extruded polymer is less than about 0.80 of the total parison thickness.
  • the one or more additional extruded polymer layers comprise recycled or reground material.
  • the lower IV polymer has an IV between about 0.80 and about 0.85.
EP13741541.0A 2012-01-25 2013-01-24 Extruded pet parison and manufactured container Active EP2807082B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
PL13741541T PL2807082T3 (pl) 2012-01-25 2013-01-24 Wytłaczana kształtka wstępna z PET i wyprodukowany pojemnik

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US201261590652P 2012-01-25 2012-01-25
PCT/US2013/022992 WO2013112736A2 (en) 2012-01-25 2013-01-24 Extruded pet parison, container, and method

Publications (3)

Publication Number Publication Date
EP2807082A2 EP2807082A2 (en) 2014-12-03
EP2807082A4 EP2807082A4 (en) 2016-10-12
EP2807082B1 true EP2807082B1 (en) 2018-08-01

Family

ID=48874065

Family Applications (1)

Application Number Title Priority Date Filing Date
EP13741541.0A Active EP2807082B1 (en) 2012-01-25 2013-01-24 Extruded pet parison and manufactured container

Country Status (9)

Country Link
EP (1) EP2807082B1 (pl)
AU (2) AU2013212113B2 (pl)
CA (1) CA2862510C (pl)
ES (1) ES2689778T3 (pl)
MX (1) MX361085B (pl)
PL (1) PL2807082T3 (pl)
PT (1) PT2807082T (pl)
TW (1) TW201347953A (pl)
WO (1) WO2013112736A2 (pl)

Cited By (1)

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WO2021185757A1 (de) 2020-03-16 2021-09-23 Alpla Werke Alwin Lehner Gmbh & Co. Kg Verfahren zur herstellung eines zur verwendung in einem extrusionsblasverfahren geeigneten pet-ausgangsmaterials und im extrusionsblasverfahren hergestellter hohlkörper

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* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2021185757A1 (de) 2020-03-16 2021-09-23 Alpla Werke Alwin Lehner Gmbh & Co. Kg Verfahren zur herstellung eines zur verwendung in einem extrusionsblasverfahren geeigneten pet-ausgangsmaterials und im extrusionsblasverfahren hergestellter hohlkörper

Also Published As

Publication number Publication date
WO2013112736A2 (en) 2013-08-01
PT2807082T (pt) 2018-11-09
AU2017210616A1 (en) 2017-08-24
PL2807082T3 (pl) 2019-03-29
MX2014008971A (es) 2015-03-19
CA2862510A1 (en) 2013-08-01
EP2807082A4 (en) 2016-10-12
ES2689778T3 (es) 2018-11-15
MX361085B (es) 2018-11-27
EP2807082A2 (en) 2014-12-03
AU2013212113B2 (en) 2017-05-04
AU2013212113A1 (en) 2014-08-14
TW201347953A (zh) 2013-12-01
CA2862510C (en) 2019-03-19
WO2013112736A3 (en) 2015-06-18

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